Method of roofing



March 3, 1964 c. c. FIGGE 3,122,862

METHOD OF ROOFING Original Filed Dec. 27, 1955 2 Sheets-Sheet lINVENTOR; CARROLL 6f F/GGE' United States Patent 3,122,862 BETHQD @FRG'OFING Carroll C. igge, 139 W. Madison St., Batnvia, Ill. (Briginalapplication Dec. 27, 1955, Ser. No. 555,636, new Patent No. 2,949,296,dated Aug. 16, 196i). Divided and this application (Pet. 12, 1959, Ser.No. 847,040 9 Claims. (Cl. )--537) This invention relates in general tothe application of a lower bituminous layer of felt roofing material inoverlapping strips and an upper offset and complete cover therefor in acontinuous single operation and is a division of application Serial No.555,636 filed December 27, 1955, and now Patent No. 2,949,206.

It has heretofore been the practice to apply a roof covering by firstlaying a number of sheets of felt in continuous overlapping relation,cementing them together and to the roof deck, and thereafter as aseparate and distinct operation, to apply a top coating of bituminousmaterial in which mineral aggregate is imbedded and applied to theexposed portions of the overlapping sheets. Often times the applicationof the mineral coating may be delayed for several days or at least untilthe overlapping layers have become cold, if they are applied with hotasphalt during which time the seams may open, the felts may Wrinkle andmineral or other material may get under the exposed lap edges to impairthe seal.

In the present invention, the upper or exposed lap edges of the sheetsor layers are coated with an adhesive even before the cementing materialfor the layers has hardened, which insures complete welding of theseams, and the coating of mineral or other material is simultaneouslyapplied following the adhesive coating of the exposed lap edges whichcompletes the roof in one operation by the Welding of the coatingmaterial applied to the upper or exposed lap edges only instead of tothe entire Width of the sheet or layer which is applied at that time.

An important object of the invention is therefore to provide a new andimproved method of applying a roof of the laminated layer and topcoating type, complete in one operation.

A further object of the invention is to apply a mineral covering layerto a laminated roof mat at the same time the last layer is being appliedand to cover the net exposed portion of the overlap at the upper edge ofthe last lap only depending upon the number of layers which are beingapplied.

A further object of the invention is to provide an improved method ofroofing in which successive plies of roofing material are cemented to aroof deck and to each other in overlapping relation, and a top coatingis applied laterally beyond and upon the overlapping edge of the lastply, thereby welding it to the remainder of the cover at the same timethat the last sheet is being applied so that a roof is always completedup to the extent of application of the last layer.

Still a further object of the invention is the method of applying astrip of roofing and also a strip of cover material extending laterallybeyond and overlapping the inner edge of the strip thereon being appliedto a roof and underlying layer of roofing material.

Still a further object of the invention is to provide a method ofapplying a strip of roofing to a roof deck or an underlying layer andalso to apply a cover coating to extend laterally beyond and over thelapping edge of this strip in either direction of application relativeto the length of the strip.

A further object of the invention is to provide a method for cementing astrip of roofing material in place on a roof deck and successively uponunderlying plies of the material, and to adhesively apply a covercoating of material for a portion of the width of the strip of roofingat the same time and extending beyond the overlap and sealing the innerexposed edge of the strip.

Further objects of the invention are applying roofing strips to theadhesive under tension, for subsequently applying an adhesive coatingextending laterally beyond and overlapping the inner edge of a strip andthe exposed portion of the roofing strip below it as the last strip isbeing applied; and thereafter applying a mineral coating to the adhesiveon top of and extending laterally beyond the inner edge of the strip andsealing the inner lap edge of the strip.

Other objects of the invention will appear in the specification and willbe apparent from the accompanying drawings in which:

FIG. 1 is a plan view of a roof showing an apparatus and illustratingthe method in which the roof is applied in accordance with the presentinvention;

FIG. 2 is an inside elevation of the apparatus in accordance with FIG. 1showing some of the parts in section;

FIG. 3 is a plan view of the apparatus in accordance with this inventionas taken on the line 3-3 of FIG. 2 with some of the parts broken awayand shown in sec tion;

FIG. 4 is a sectional view of a roof covering as applied to a roof deckin accordance with this invention;

FIG. 5 is a sectional plan view of an apparatus in accordance with thisinvention having a modified adhesive feed, as taken on the line 5 ofFIG. 6;

FIG. 6 is a side elevation of the structure shown in FIG. 5, with partsbroken away and in section; and

FIG. 7 is a perspective View of part of the adhesive feeding means shownin FIGS. 5 and 6.

In carrying out this invention, a single machine is loaded with roofingmaterial, adhesive, and a coating material and may be moved manually orby motor over a roof deck to be covered. As it is so moved, the roofwill be completed, sealing all lapped and exposed edges as the machineis moved, and up to the last of such movement, leaving only that portionof the last layer which is not completely covered by the coatingmaterial, but may be finished by hand or in an operation separate fromthis. machine.

Referring now more particularly to the drawings, a waterproof andprotective roof covering is applied to a roof deck 19 by cementing aplurality of strips 12 of roofing material to the roof deck and to eachother in overlapping relation by means of an adhesive coating 13 at thebottom of the strip and extending the full width thereof, and thenapplying an adhesive coating 14 on top of a portion of the stripsoverlying and extending beyond the inner edge of the strip last appliedand applying a protective coating 16 if desired to the adhesive coating14.

As heretofore practiced, these operations have been manual and separate,the strips being first adhesively applied to the deck in overlappingrelation to the other strips, and after the application of all or aportion of the layers, a batch of adhesive coating was applied to anarea and after this application a protective coating of gravel, cindersor other mineral material was applied to the outer adhesive coating as aseparate or batch operation.

Sometimes these operations were hours and even days apart, and theoverlying strips which are usually applied with a hot bituminousadhesive are cooled or become set before the outer adhesive coating andthe protective coating are applied. In this manner, the overlappingedges of the uppermost coatings may become torn or projections may belodged under them which tend to puncture or destroy the waterproofprotection afiorded by the roofing strips, and when the outer adhesiveand protecting coatings are later applied, the projecting edges may not3 be properly cemented down and attached to the roofing material.

In the present invention, the roofing strips 12 are applied in multipleoverlapping relation and adhesive coating 13 is applied to the underside of each strip for its full Width, and at the same time an adhesivecoating is applied on top of this strip as it is being laid for aportion of the width thereof extending beyond and overlapping theinnermost or uppermost edge of the last strip to which a protectivecoating of gravel or other material is applied covering the upperlapping edge of the last strip and extending laterally beyond it so thatit is welded in place by the coating material in hot condition, and theroof is completed in one operation simultaneously applying a stripforming a body of the roof and a roof surfacing therefor extendingbeyond the upper or inner edge of the last strip and depending upon theamount of overlap of the last strip.

In considering the amount of overlap, the width of a roofing strip maybe taken as approximately 36" so that for three thicknesses of roofingmaterial, the net amount of overlap of each added strip to which thefinal surfacing is applied will be approximately one-third of 36" or12"; for an overlap of four layers, the approximate net overlap will beabout 9", etc. As shown in FIG. 4, the strips have a one-third netoverlap, and the thickness of the main portion of the roofing is threelayers of strips 12. In commencing the first, second and third layers ofa roof, and likewise in finishing the last two or three layers of aroof, some manual operation may be necessary, but by employing acontinuous operating and finishing method as described and shown herein,a large area of roof can be covered and completed at each operation, inwhich the strips 12, the adhesives 13 and 14 and the protective coatingapplied beyond the upper edge of the strip 12 and overlapping this edge,are applied continuously and simultaneously finishing the roof up tothis point.

A suitable apparatus for carrying out this method and operationcomprises a wheeled supporting frame 18 in which each wheel 20 isindividually adjustable in a wheel mounting attached at the under sideof the frame and having an axle 24 engaged by upper and lower adjustingscrews 26 and 28, so that the height of each Wheel may be varied in itsmounting 22. This adjustment'is valuable for maintaining the frame 13 indifferent spaced horizontal positions with respect to the roof dependingupon whether the covering is composed of a single layer or many layersof material. This permits adjustments of the wheels on one side of theframe to run on the roof deck and the wheels on the other side of theframe to run on top of the applied layers, so that the roofing materialsare evenly applied as the wheeled frame is moved over a roof deck in onedirection or the other.

Supported at opposite sides of the frame 18 are bearings 32 forreceiving a transverse shaft 34 upon which a roll 3d of roofing paper,felt or other material is mounted so that a continuous strip 38 of theroof material may be discharged from the roll 36 as the frame is movedover a roof deck in the direction of the arrow as shown in FIGS. 1 and2. V

In advance of the roll 36 and mounted in the frame 13 by suitableframing or cross pieces 40 is a receptacle 42 which may be graduated inwidth from the bottom to the top and constructed of suitable metal orother material for containing an adhesive 44 preferably hot bituminousmaterial commonly used for cementing roofing upon roof decks. At thebottom is a suitable valve (or valves) 46 for controlling the dischargeof adhesive 44 from the receptacle 42 preferably for the full width ofthe strip 38, but also distributing less than the full width if a numberof valves 46 are employed.

A number of Spreaders 48 are mounted between the receptacle 42 and theroll 36 which are connected to a cross piece 55 These sprcaders engagethe adhesive as it is discharged from the receptacle 42 and distributethe adhesive more evenly for engagement with the under side of the strip33 from the roll 36. The height of the spreaders is controlled bysupports 52 attached at each side of the cross piece 5% and each havinga wing nut 54 for adjustably attaching it to one of the cross pieces 49of the wheel frame adjacent to the roll 36. Extending transversely ofthe frame 18 is a pressing device which may be in the form of a brush 56extending the full width of a strip 58 and engaging the upper surfacethereof. This brush may be supported by two or more upwardly extendingrods 58 extending into a sleeve 6% closed at its upper end, the sleevebeing supported by a cross piece 62 in the frame 18 and each sleevehaving an extended coil spring 64 engaging the upper end of the sleeveat one end, surrounding the rod 58 and bearing on a projection or collar66 mounted near the lower end of the rod. The arrangement of the brushand its mounting is such that it is pressed yieldingly against the uppersurface of a strip 38 for sealing it more smoothly in the adhesive 13 atthe under side of the strip as it is applied to a roof deck and to anystrips which it overlaps.

Another adhesive receptacle 68 is mounted in the wheeled frame 18 bymeans of cross pieces 79. It may also be tapered toward the bottom andconnected to the adhesive receptacle 42 by a transfer duct 72 whichprovides a wide passageway for the free movement of the adhesive fromone receptacle to the other. At the bottom of this receptacle 68 arethree discharge portions 74, 76 and '78, the two side portions 74 and 76covering a limited portion at each edge of a strip 38 which is beinglaid and overlapping the edge, and the discharge portion 75 covering thecentral portion of the strip. Each of these portions is provided withsuitable valves 30 for controlling the discharge and fiow of adhesivefor that particular dis charge opening to which it is applied. In thismanner, the discharge of the adhesive can be controlled to cover alimited portion at each side of the strip which is being applied to aroofing and over the edge thereof depending upon the direction ofmovement of the apparatus with respect to the strip, and also permittingapplication of adhesive to the central portion of the strip if desired.

Attached to the trailing cross piece 70 following the receptacle 68 areSpreaders 32 similar to the spreaders 48 supported by rods 84 andadjustable by means of wing nuts 86. With this arrangement, thespreaders may be arranged depending upon which valves are opened at anyparticular time.

At the rear end of the wheeled frame is a mineral'adhesive receptacle 88for containing sand, ashes, gravel or other mineral aggregate which isapplied to the roof as a covering coating. This receptacle is taperedupwardly in size and is mounted in cross pieces 94 of the frame withinclined seating surfaces corresponding to the inclination of thereceptacle 88 so that it may be bodily moved from one side to the otherof the frame to discharge mineral ingredients 92 at the bottom through asuitable valve 94. This receptacle 88 is preferably less in width thanthe adhesive receptacles 42' and 68 as it is ordinarily intended todischarge the protective coating 16 over a limited width of the roofingmaterial approximately equal to the net amount of overlap of each strip,but applied'over the upper most edge portion of the last strip as it isbeing applied, extending laterally therefrom and partially overlappingthe next strip below it as more clearly indicated in FIG. 4.

When the wheeled truck carrying the apparatus is moved in one directionover the roofing as it is applied, the mineral receptacle 88 will belocated at one side of the frame 13 and when the movement of the wheeledtruck is reversed in direction in applying the next strip, the mineralreceptacle 88 is moved to the other side of the truck as indicated moreclearly in FIG. 3.

Instead of having two separate receptacles for the adhesive 44, a singlereceptacle 96 may be provided for the wheeled frame as shown in FIGS. 5,6 and 7. This receptacle may be mounted in cross pieces 40 as previouslyexplained and has discharge valves 46 at the bottom, the spreaders 48, aroll 36 of roofing material, and a pressure device 56 similar to thatpreviously described.

Instead of the separate receptacle for feeding adhesive on top of thestrips as they are cemented in place, di charge pipes 98 are connectedinto the receptacle 96 at opposite sides of the wheeled truck but at thesame and relatively inner side of the receptacle. These pipes lead toseparate discharge casings 1% through control valves 102 therefor, thecasings having openings 104 for discharging the adhesive therefrom.Between the side casings 100 is a separate central casing 196 which hasa branch pipe 108 leading from one of the other pipes 92 through a valve110 for separately controlling the supply of adhesive to this centralcasing.

With this arrangement, it is also contemplated that two separate mineralsupply receptacles 112 are provided, one at each side of the wheeledframe and in line with the corresponding casing 169 for dischargingadhesive at that side of the frame.

As in the previous arrangement of the parts, spreaders 82 will belocated following the adhesive discharge from the casings 100 or 106.This latter arrangement obviates the necessity of a separate adhesivetank and thereby simplifies the apparatus mounted on the wheeled frameto that extent. In reversing the movement of this form, it is notnecessary to move the mineral aggregate receptacle from one side of thewheeled frame to the other. If the central casing 106 is used for theapplication of adhesive in its path, a separate aggregate receptacle maybe mounted to discharge between the two mineral supply receptacles 112as shown in FIG. 5, but ordinarily this is not necessary as mineralsupply from one or both of the receptacles 112 may be discharged fromthem and manually spread over the adhesive from the central receptacle166 as desired.

With this latter arrangement of the parts as shown in FIGS. 5, 6 and 7,the method of operation is essentially the same as in the operationpreviously described except that it is somewhat simpler to supply andcontrol the adhesive applied on top of a strip of roofing as it is beinglaid in place, and it is not necessary to move the mineral supply ofreceptacle from one side of the wheeled frame to the other when theWheeled frame is reverse in its direction of movement.

When this apparatus is in use, additional supplies of the adhesive andalso the mineral aggregate may be applied to their respectivereceptacles while the wheeled frame is in motion, or while it is beingreversed in direction at the end of its path. This is commonly done bymanually emptying buckets of the material into the receptacles and toprevent splashing and loss of the materials, an antisplash guard 114 islocated near the top of each receptacle extending lengthwise therein andcurved downwardly from the crown portion at the top leaving spaces atthe sides for the material to run down into the receptacle. Each guardis supported at the ends of the receptacle by suitable brackets 116 forholding it firmly in place. With these guards, the materials may bedeposited into the tops of the receptacles and they will run down thesides of the guard and against the adjacent sides of the receptacleswithout causing a splash or discharge of the materials outside of thereceptacles which might land on the roof deck and interfere with theproper application of the roofing and its covering.

This invention is not limited to the laying of strips in successiveoverlapping courses but may be applied to felt strips laid in separatecourses overlapping a small amount for each complete layer and thenapplying one or more other separate layers of this same kind insuccessive operations. It may likewise be applied to various other striplaying patterns. The adhesive material may be of either hot or coldapplication, the only requisite being that it flows freely and providesa satisfactory adhesive coating. In some cases, a mineral aggregate isnot applied as a cover coating but an adhesive or bituminous coatingeither of limited width or the full width of the felt cover strip may beapplied. The last sheet of a roof application may be coated on top forits full width and mineral aggregate may be distributed at oppositesides and separately spread to cover the middle portion if desired.Other patterns of sheet application and adhesive and cover coatinglayers are apparent and possible in this method and apparatus.

While a preferred method of completing a roof covering in one operationand apparatus for accomplishing this has been described in some detail,they should be regarded as illustrations or examples rather than aslimitations or restrictions of the invention, since various changes inthe construction, combination, and arrangement of the parts may be madewithout departing from the spirit and scope of the invention.

I claim:

1. A method of completely finishing a portion of a multi-layer roofingby simultaneously applying an overlapping ply of prepared roofing and asurface covering therefor, which comprises cementing successive layersof prepared roofing materials in overlapping relation on a roof deck andpreviously laid layers, and at the same time applying a layer of surfacecovering material upon the lap edge or" the last layer spreading anadhesive underneath the layer for the full Width thereof, spreading alayer of surface covering material overlapping the top edge of saidroofing layer of a width equal to that portion of the cover material andlaterally displaced therefrom to cover a portion of a previous layer ina width equal approximately to the net overlap of each layer.

2. The method of applying a portion of a roof covering complete in onesimultaneous operation and in an adjacent location, which comprisescementing strip layers of roofing material in successive overlappingrelation to each other and to a roof deck, and simultaneously applyingan adhesive layer of covering material to the lap edge of the last layerat a distance from said cementing and partially overlapping the previouslayer in a width equal approximately to the amount of contact of thelast strip with the roof deck.

3. The method of completely finishing part of a multilayer roofing byapplying a complete portion thereof having roofing strip material andcovering material in adjacent places by a joint operation whichcomprises applying successive layers of strip material from a commonsupply in overlapping relation to each other and to a roof deck,simultaneously applying a layer of covering material to the lap edge ofthe last layer and laterally displaced therefrom so as to extendinwardly beyond the edge in a width approximately equal to the netamount of lap of each overlapping layer, and applying an adhesive beloweach strip layer as it is applied to the roof and on top of a portion ofthe last strip layer and extending beyond the edge thereof beyond theupper lap edge and of a width equal to the net amount of the overlap.

4. The method of completely finishing a portion of a multi-layer roofwherein the body of the roof and the roof surfacing medium are appliedsimultaneously in adjacent places, which comprises applying separatestrips of roofing material in successive overlapping layers andadhesively attaching the entire lower surface of each layer to a roofdeck and to the layer below the contact of the last layer with the roofdeck, measuring the width of the overlap of each strip, applying anadhesive to the top of the last strip, covering the exposed lap portionof this strip and extending laterally therefrom in a width substantiallyequal to the net overlap width of the strip as applied to the roof, andsimultaneously applying a coating of covering material, to the adhesiveapplied on top of a portion of the width of the strip and extending overand laterally beyond the inner edge thereof.

5. In a method of completely finishing a portion of a multi-layer roofin accordance with claim 4, the step of spreading the adhesive which isapplied to the under side of the last layer so that it will be uniformlydistributed and applied thereto.

6. In the method of completely applying a portion of a multi-layer roofcovering in accordance with claim 4, the additional step of spreadingthe adhesive which is applied to a portion of the width of the top ofthe last strip and extending laterally therefrom so that it will beevenly spaced for the attachment of the coating of covering materialwhich is applied to the outside of the last strip.

7. In the method of completely finishing a portion of a multi-layerroofing in accordance with claim 4, the step of pressing the last layerresiliently against the deck and the preceding layers to smooth the lastlayer for the application of the adhesive, and covering the materialapplied for a reduced width on top of the layer with a thin protectivelayer. a

8. The method of completely finishing a portion of a multi-layer roofingby applying a portion of the body of the roof and a correspondingportion of the roof surfacing material in one simultaneous operation inadjoining locations, which comprises applying strip layers of roofingmaterial in successive overlapping relation to each other and to a roofdeck, depositing an adhesive below each layer as it is applied to thedeck and a previous layer, spreading the deposited adhesive to equalizeit in thickness for application to the layer, pressing the last layerresiliently against the deck and the preceding layers, applying adhesivematerial to the overlapping edge and for a portion of the Widthlaterally spaced outwardly therefrom over the preceding layer in a widthsubstantially equal to the net width of contact of this strip with theroof deck, spreading the adhesive applied to the overlap and to thelimited width outwardly from the last layer in a uniform sheet, andapplying a thin coating of protective material to the last adhesivecoating to complete a portion of the roof up to that point equal to theamount of the overlap.

9. The method of completing a portion of a multilayer roofing in onecontinuous and simultaneous operation which comprises moving a supply ofsheet roofing material and adhesive therefor over a roof deck to becovered, discharging successive strips of the sheet material from thesupply and applying them in successive overlapping layers to each otherand to the roof, applying and spread ing a coating of adhesive inadvance of the roofing strips to adhesively secure them to each otherand to the roof, resiliently pressing each strip in contact with theroof and, a previously applied strip as-the said roofing strip isapplied, applying a coating of adhesive over the upper lap edge of eachroofing strip and displaced laterally outwardly beyond the edge as it isapplied to applied strips in' a width substantially equal to the netamount of overlap of each strip, spreading the said lap adhesive as theroofing strip is applied, and continuously applying a protective coatingwhich adheres to the last said layer of lap adhesive and therebycompleting the last portion of the roof to this point.

References Cited in the file of this patent UNITED STATES PATENTS236,386 Warren Jan. 4, 1881 296,163 Haas Apr. 1, 1884 805,746 Pease Nov.28, 1905 822,602 Gross et a1. June 5, 1906 1,044,773 Gillett Nov. 19,1912 1,151,096 French Aug. 24, 1915 1,298,690 Goldberg Aug. 1, 19191,427,755 Harris Aug. 29, 1922 1,979,656 Whitman Nov. 6, 1934 2,144,168Sherritt Ian. 17, 1939 2,197,878 Robinson Apr. 23, 1940 2,280,579 HardyApr. 21, 1942 2,373,239 Fenn Apr. 10, 1945 2,500,583 Smith Mar. 14, 19502,898,825 Walker et al Aug. 11, 1959 FOREIGN PATENTS 265,081 GreatBritain Feb. 3, 1927 494,231 Great Britain Oct. 20, 1938 p

1. A METHOD OF COMPLETELY FINISHING A PORTION OF A MULTI-LAYER ROOFINGBY SIMULTANEOUSLY APPLYING AN OVERLAPPING PLY OF PREPARED ROOFING AND ASURFACE COVERING THEREFOR, WHICH COMPRISES CEMENTING SUCCESSIVE LAYERSOF PREPARED ROOFING MATERIALS IN OVERLAPPING RELATION ON A ROOF DECK ANDPREVIOUSLY LAID LAYERS, AND AT THE SAME TIME APPLYING A LAYER OF SURFACECOVERING MATERIAL UPON THE LAP EDGE OF THE LAST LAYER SPREADING ANADHESIVE UNDERNEATH THE LAYER OF THE FULL WIDTH THEREOF, SPREADING ALAYER OF SURFACE COVERING MATERIAL OVERLAPPING THE TOP EDGE OF SAIDROOFING LAYER OF A WIDTH EQUAL TO THAT PORTION OF THE COVER MATERIAL ANDLATERALLY DISPLACED THEREFROM TO COVER A PORTION OF A PREVIOUS LAYER INA WIDTH EQUAL APPROXIMATELY TO THE NET OVERLAP OF EACH LAYER.